Saw blade

ABSTRACT

A saw blade includes a body and a plurality of cutting teeth formed on the body. Each cutting tooth includes a tip at a first end of the cutting tooth, a rake face extending from the tip toward the body, a relief face extending from the tip toward a second end of the cutting tooth and sloping toward the body, and a projection at the second end of the cutting tooth and sloping away from the body. The saw blade also includes a plurality of gullets formed on the body between the plurality of cutting teeth. Each gullet forms an undercut portion between the body and the projection of each cutting tooth.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/249,936, filed Nov. 2, 2015, and U.S. Provisional PatentApplication No. 62/374,256, filed Aug. 12, 2016, the entire contents ofwhich are incorporated herein by reference.

BACKGROUND

The present invention relates to saw blades and, more particularly, toreciprocating saw blades with carbide inserts.

SUMMARY

In one embodiment, a saw blade includes a body and a plurality ofcutting teeth formed on the body. Each cutting tooth includes a tip at afirst end of the cutting tooth, a rake face extending from the tiptoward the body, a relief face extending from the tip toward a secondend of the cutting tooth and sloping toward the body, and a projectionat the second end of the cutting tooth and sloping away from the body.The saw blade also includes a plurality of gullets formed on the bodybetween the plurality of cutting teeth. Each gullet forms an undercutportion between the body and the projection of each cutting tooth.

In another embodiment, a method of manufacturing a saw blade includesproviding a saw blade body and forming a plurality of tooth bodies inthe saw blade body. Each tooth body includes a rake face extending froma first end of the tooth body toward the saw blade body, a relief faceextending from the first end of the tooth body toward a second end ofthe tooth body and sloping toward the saw blade body, and a projectionat the second end of the tooth body and sloping away from the saw bladebody. The method also includes forming a plurality of gullets in the sawblade body between the plurality of tooth bodies. Each gullet forms anundercut portion between the saw blade body and the projection of eachtooth body.

In another embodiment, a saw blade includes a body and a plurality ofcutting teeth formed on the body. Each cutting tooth includes a firsttip at a first end of the cutting tooth, a first rake face extendingfrom the first tip toward the body, a second tip at a second end of thecutting tooth, and a second rake face extending from the second tiptoward the body. The first rake face has a first linear segmentextending from the first tip and a first curved segment between thefirst linear segment and the body. The second rake face has a secondlinear segment extending from the second tip and a second curved segmentbetween the second linear segment and the body. The saw blade alsoincludes a plurality of gullets formed on the body between the pluralityof cutting teeth. Each gullet forms a first undercut portion at thefirst curved segment of one of the plurality of cutting teeth and asecond undercut portion at the second curved segment of an adjacentcutting tooth.

In another embodiment, a method of manufacturing a saw blade includesproviding a saw blade body having an edge, coupling a carbide strip tothe edge of the saw blade body, and forming a plurality of cutting teethin the carbide strip and the saw blade body after the carbide strip iscoupled to the edge. Each cutting tooth includes a first tip at a firstend of the cutting tooth, a first rake face extending from the first tiptoward the saw blade body, a second tip at a second end of the cuttingtooth, and a second rake face extending from the second tip toward thesaw blade body. The first rake face has a first linear segment extendingfrom the first tip and a first curved segment between the first linearsegment and the saw blade body. The second rake face has a second linearsegment extending from the second tip and a second curved segmentbetween the second linear segment and the saw blade body. The methodalso includes forming a plurality of gullets in the saw blade bodybetween the plurality of cutting teeth. Each gullet forms a firstundercut portion at the first curved segment of one of the plurality ofcutting teeth and a second undercut portion at the second curved segmentof an adjacent cutting tooth.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a saw blade embodying the invention.

FIG. 2 is an enlarged side view of a portion of the saw blade of FIG. 1.

FIG. 3 is a cross sectional view of the saw blade taken along 3-3 ofFIG. 1.

FIG. 4 is an enlarged view of a portion of the saw blade of FIG. 3.

FIG. 5 illustrates a method of manufacturing the saw blade of FIG. 1.

FIG. 6 illustrates a method of manufacturing a saw blade according toanother embodiment of the invention.

FIG. 7 illustrates a saw blade body.

FIG. 8 illustrates tooth bodies and gullets formed in the saw bladebody.

FIG. 9 illustrates cutting inserts coupled to the tooth bodies of FIG. 8to form cutting teeth.

FIG. 10 is an enlarged view of portions of the saw blade of FIG. 9illustrating the cutting teeth and the gullets.

FIG. 11 illustrates a method of manufacturing a saw blade according toanother embodiment of the invention.

FIG. 12 illustrates a saw blade body.

FIG. 13 illustrates a carbide strip coupled to the saw blade body.

FIG. 14 illustrates cutting teeth formed in the carbide strip and thesaw blade body with gullets formed between the cutting teeth.

FIG. 15 is an enlarged view of portions of the saw blade of FIG. 14illustrating the cutting teeth and the gullets.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Unless otherwise stated, the term“approximately” as used herein refers to values that are within normalmanufacturing tolerances of saw blades.

DETAILED DESCRIPTION

FIG. 1 illustrates a saw blade 10. The saw blade 10 includes a saw bladebody 14 having a plurality of cutting teeth 18 formed thereon. The sawblade 10 also includes an attachment portion 22 extending from the sawblade body 14. The attachment portion 22 has a tang 26 and an aperture30 for connecting the saw blade 10 to a reciprocating saw (not shown).Before the cutting teeth 18 are formed on the saw blade body 14, the sawblade body 14 is considered to be a saw blade blank. A “blank” refers toa piece of material (e.g., steel coil stock) that is used to form a sawblade before the saw blade is complete (e.g., before the saw blade isfully formed with cutting teeth).

FIG. 2 illustrates three of the cutting teeth 18 in more detail. All ofthe cutting teeth 18 on the saw blade 10 are generally the same shapeand size. Each cutting tooth 18 includes a tip 34 at a first end 36 ofthe cutting tooth 18, a rake face 38 adjacent the first end 36, and arelief face 42 extending toward a second end 44 of the cutting tooth 18.Each tip 34 is formed by a cutting insert 46 secured to a tooth body 50(i.e., the remainder of the cutting tooth 18). In the illustratedembodiment, each cutting insert 46 is a carbide insert, and each toothbody 50 is formed of steel (e.g., the saw blade body 14 is formed ofsteel). In other embodiments, the cutting inserts 46 may be omitted sothat each tip 34 is formed from a portion of each tooth body 50. Theillustrated inserts 46 may be secured to the tooth body 50 byconventional techniques, such as resistance welding, brazing, etc.

As shown in FIGS. 3 and 4, the cutting inserts 46 include an insertwidth W₁ that is slightly wider than a tooth body width W₂ of the toothbodies 50. For example, each cutting insert 46 has a width W₃ thatextends between approximately 0.01 millimeters to approximately 0.03millimeters on both sides of each tooth body 50. In addition to or as analternative to the cutting inserts 46 being wider than the tooth bodies50, the cutting teeth 18 may be set in any desired pattern.

With reference back to FIG. 2, the rake faces 38 extend from each tip 34generally toward a longitudinal axis 54 of the saw blade body 14. Thelongitudinal axis 54 is a linear axis extending along the length of thesaw blade body 14. In other embodiments, the longitudinal axis 54 may becurved to wrap around the body of, for example, a hole saw. Eachillustrated rake face 38 is defined partially by one cutting insert 46and partially by one tooth body 50. In the illustrated embodiment, therake faces 38 are oriented at a first angle θ₁ (e.g., approximately 85degrees) relative to the longitudinal axis 54 of the saw blade body 14.In other embodiments, the rake faces 38 may be angled at any otherdesired positive, negative, or zero rake angle.

With continued reference to FIG. 2, the relief faces 42 also extend fromeach tip 34, but generally toward the next successive cutting tooth 18.In particular, the illustrated relief faces 42 extend linearly from eachtip 34 and are sloped or angled toward the saw blade body 14. Similar tothe rake faces 38, the relief faces 42 are defined partially by onecutting insert 46 and partially by one tooth body 50. In the illustratedembodiment, each relief face 42 is oriented at a second angle θ₂ (e.g.,approximately 10 degrees) relative to the longitudinal axis 54 of thesaw blade body 14. In other embodiments, each relief face 42 may beangled at a greater or lesser angle, or each relief face 42 may be atleast partially curved.

As shown in FIG. 2, each cutting tooth 18 also includes a materiallimiter 58 at the second end 44 of the cutting tooth 18. Each materiallimiter 58 is a projection formed at a distal end 62 of each relief face42 opposite from each tip 34. The material limiters 58 extend toward thenext successive cutting tooth 18. In the illustrated embodiment, eachmaterial limiter 58 is sloped away from the longitudinal axis 54 of thesaw blade body 14 relative to each relief face 42 (i.e., upwardly inFIG. 2). In addition, each material limiter 58 has a rounded end 66facing the next successive cutting tooth 18.

The illustrated material limiters 58 are sloped at a smaller angle thanthe angle of the relief faces 42 so that an apex 70 of each limiter 58is closer to the tips 34 of the cutting tooth 18 than the saw blade body14. More particularly, the tips 34 of the cutting teeth 18 define aplane 74 that is generally parallel to the longitudinal axis 54 of thesaw blade body 14, and the apexes 70 of the material limiters 58 arespaced a vertical distance V from the plane 74 measured in a verticaldirection perpendicular to the longitudinal axis 54 and to the plane 74.In the illustrated embodiment, the vertical distance V is approximately0.25 millimeters. In other embodiments, the vertical distance V may belarger or smaller than 0.25 millimeters. In addition, the apexes 70 ofeach material limiter 58 are positioned between the distal end 62 of therelief faces 42 and the plane 74 in the vertical direction perpendicularto the plane 74. In the illustrated embodiment, the apex 70 of eachmaterial limiter 58 is also positioned between each distal end 62 of therelief faces 42 and each rounded end 66 of the material limiters 58 in ahorizontal direction parallel to the plane 74. The illustrated apexes 70of the cutting tooth 18 are also spaced a horizontal distance H from therake faces 38 of the next successive cutting tooth 18. The horizontaldistance H is measured in a direction perpendicular to the rake faces 38of each cutting tooth 18. In the illustrated embodiment, the horizontaldistance H is approximately 12.5 millimeters. In other embodiments, thehorizontal distance H may be larger or smaller than 12.5 millimeters.

As also shown in FIG. 2, gullets 78 are formed on the saw blade body 14between the cutting teeth 18 (e.g., the rake face 38 of one cuttingtooth 18 and the material limiter 58 of another cutting tooth 18partially define a gullet 78 between two successive cutting teeth 18).The illustrated gullets 78 include an undercut portion 82 that is formedbetween the material limiter 58 and the saw blade body 14 (i.e., beneaththe material limiter 58 in the vertical direction). In particular, eachillustrated undercut portion 82 is defined by a rear edge 86 having afirst curvature of each tooth body 50. The undercut portions 82 arearranged so that the rounded end 66 of each material limiter 58 ispositioned between the undercut portion 82 of one cutting tooth 18 andthe tip 34 of an adjacent cutting tooth 18 in the horizontal directionparallel to the longitudinal axis 54. The gullets 78 are also defined bya forward edge 90 having a second curvature of each tooth body 50. Thefirst curvature of the rear edge 86 and the second curvature of theforward edge 90 have a constant radius so that the illustrated gullets78 are generally circular. The undercut portions 82 increase the size ofthe gullets 78, yet still allow the material limiters 58 to extendrelatively close to the cutting inserts 46 of the next successivecutting tooth 18. In the illustrated embodiment, a first distancedefined between the rounded end 66 of each material limiter 58 and thetip 34 of an adjacent tooth body 18 is less than a second distancebetween the rear edge 86 of each cutting tooth 18 and the rake face 38of an adjacent cutting tooth 18.

With reference to FIG. 5, a method 94 of manufacturing the saw blade 10is illustrated. A blank saw blade body 14 (e.g., omitting the toothbodies 50 and the gullets 78) is provided (step 98) so that the toothbodies 50, the gullets 78, and the attachment portion 22 aresimultaneously formed by a stamping process in the saw blade body 14(steps 102, 106, 110). The stamping process is advantageous (e.g.,quicker) over other machining processes (e.g., milling, grinding, etc.)to facilitate formation of the gullets 78 with the undercut portions 82.In some embodiments, the attachment portion 22 may be formed in the sawblade body 14 after or before the tooth bodies 50 and the gullets 78 areformed in the saw blade body 14. In other embodiments, the tooth bodies50, the gullets 78, and/or the attachment portion 22 may be formed byanother process (e.g., laser cutting). After the tooth bodies 50 and thegullets 78 are formed in the saw blade body 14, the cutting inserts 46are secured (e.g., welded, brazed, etc.) to the tooth bodies 50 (step114).

During cutting operations (e.g., when the saw blade 10 is reciprocatedback and forth generally along the longitudinal axis 54 by areciprocating saw), each material limiter 58 reduces or limits thatamount of material that the next successive tooth 18, and particularlythe cutting insert 46 of the next successive tooth 18, will encounter.In particular, the material limiters 58 guide the material being cutinto adjacent cutting teeth 18 so only a relatively small amount ofmaterial contacts the cutting inserts 46. For example, the verticaldistance V between the apexes 70 of the material limiters 58 and thetips 34 of the cutting teeth 18 limit the amount of material to 0.25millimeters, which is equal to the vertical distance V. This isparticularly useful when cutting hard materials, such as metal, that mayotherwise break or damage the cutting inserts 46. The relatively largergullets 78 with the undercut portions 82 provide adequate chip removalbetween cutting teeth 18, even with the material limiters 58 spacedrelatively close to the tips 34 of adjacent cutting teeth 18.

In some embodiments, the cutting speed and durability of the cuttinginserts 46 may be adjusted by changing the vertical distance V. Forexample, increasing the vertical distance V between the apexes 70 of thematerial limiters 58 and the tips 34 of the cutting teeth 18 mayincrease the cutting speed of the saw blade 10, but lower the durabilityof the inserts 46. Conversely, decreasing the vertical distance Vbetween the apexes 70 of the material limiters 58 and the tips 34 of thecutting teeth 18 may increase the durability of the cutting inserts 46,but reduce the cutting speed of the saw blade 10.

In the illustrated embodiment, the saw blade 10 includes five teeth perinch (i.e., TPI). In other embodiments, the saw blade 10 may includefewer or more TPI (e.g., four TPI, six TPI, or any fractional number ofTPI between four and six). The addition of material limiters 58 and thegullets 78 with the undercut portions 82 to the saw blade 10 allow thesaw blade 10 to be manufactured with fewer teeth per inch (e.g., 4-5 TPIvs. 6 TPI in conventional saw blades) so that fewer cutting inserts 46,which are relatively expensive, need to be included on the saw blade 10.In addition, the material limiters 58 help protect the cutting inserts46 from damage.

FIGS. 6-10 illustrate a saw blade body 214 (FIG. 7) that is formed intoa saw blade 210 (FIG. 9) according to an embodiment of the invention.The saw blade 210 is similar to the saw blade 10; therefore, likecomponents have been given like reference numbers plus 200 and only thedifferences between the saw blades 10, 210 will be discussed in detail.In addition, components or features described with respect to only oneor some of the embodiments described herein are equally applicable toany other embodiment described herein.

A method 294 of manufacturing the saw blade 210 is illustrated in FIG.6. At step 298, a blank saw blade body 214 (FIG. 7) having an edge 209is provided. In the illustrated embodiment, the edge 209 is parallel toa longitudinal axis 254 of the saw blade body 214.

With reference to FIG. 8, tooth bodies 250, gullets 278, and anattachment portion 222 are simultaneously formed by a stamping processin the saw blade body 214 (steps 302, 306, 310). In other embodiments,the attachment portion 222 may be formed before or after the toothbodies 250 and the gullets 278 are formed. The illustrated attachmentportion 222 includes a tang 226 and an aperture 230 for connecting thesaw blade 210 to a reciprocating saw.

With reference to FIG. 10, each illustrated gullet 278 includes a firstundercut portion 282 a defined by a forward edge 290 of the tooth bodies250 and a second undercut portion 282 b defined by a rear edge 286 ofthe tooth bodies 250. The forward and rear edges 286, 290 have aconstant radius so the illustrated gullets 278 are generally circular.Each gullet 278 defines a gullet width 211 that is greater than anopening width 213 of an opening 215 between adjacent tooth bodies 250.The gullet width 211 is measured between the first undercut portion 282a and the second undercut portion 282 b of a gullet 278. The openingwidth 213 is measured between ends of adjacent cutting teeth bodies 250.In the illustrated embodiment, a ratio between the gullet width 211 overthe opening width 213 is approximately 1.6:1. In one embodiment, theratio between the gullet width 211 over the opening width 213 isapproximately 1.77:1. In another embodiment, the ratio between thegullet width 211 over the opening width 213 may be between approximately50:1 and approximately 1.2:1. In further embodiments, the ratio betweenthe gullet width 211 over the opening width 213 may be betweenapproximately 10:1 and approximately 1.6:1. In yet further embodiments,the ratio between the gullet width 211 over the opening width 213 may bebetween approximately 2:1 and approximately 1.7:1.

Referring back to FIGS. 9 and 10, after the tooth bodies 250 and gullets278 are formed on the saw blade body 214, cutting inserts 246 (e.g., twocarbide cutting inserts 246 a, 246 b) are coupled to the tooth bodies250 (step 314) to form cutting teeth 218. Each cutting tooth 218includes a first tip 234 a at a first end 236 of the cutting tooth 218that faces away from a second tip 234 b at a second end 244 of thecutting tooth 218. Each tip 234 a, 234 b extends into the opening width213 of the opening 215.

Each cutting tooth 218 also includes a first rake face 238 a defined bythe first carbide insert 246 a and the tooth body 250. The first rakeface 238 a has a first linear segment 217 a extending from the first tip234 a toward the saw blade body 214 and a first curved segment 219 apositioned between the first linear segment 217 a and the saw blade body214. The first curved segment 219 a partially defines the first undercutportion 282 a. Each cutting tooth 218 further includes a second rakeface 238 b defined by the second carbide insert 246 b and the tooth body250. The second rake face 238 b has a second linear segment 217 bextending from the second tip 234 b toward the saw blade body 214 and asecond curved segment 219 b positioned between the second linear segment217 b and the saw blade body 214. The second curved segment 219 bpartially defines the second undercut portion 282 b. In otherembodiments, the first and second linear segments 217 a, 217 b may becurved segments. In the illustrated embodiment, a relief face 242extends between the first and second tips 234 a, 234 b.

In general, the illustrated tooth bodies 250 and the gullets 278 arestamped into the saw blade body 214 and then the cutting inserts 246 arecoupled to the saw blade body 214 forming the cutting teeth 218 suchthat a saw blade 210 is formed. The quantity of cutting teeth 218 formedon the saw blade 210 (e.g., teeth per inch) is designed to efficientlycut different work pieces. For example, a saw blade 210 having a TPI ofabout 7 or higher (smaller cutting teeth 218) is typically used forcutting metallic work pieces, and a saw blade 210 having a TPI of lessthan 7 (larger cutting teeth 218) is typically used for cutting woodwork pieces. As the teeth per inch varies, a ratio of the gullet width211 over a width of each cutting tooth 218 (e.g., a distance between thefirst and second tips 234 a, 234 b) also varies. In general, as theratio of the gullet width 211 over the width of each cutting tooth 218increases, the teeth per inch decreases. In one embodiment with a sawblade 210 including 6 teeth per inch, the gullet width 211 is about0.077 inches and the width of each cutting tooth 218 is about 0.45inches. After the saw blade 210 is formed, the saw blade 210 undergoes aprocess to remove burrs (e.g., roll-over) created from the stampingprocess and/or to form cutting edges on the cutting inserts 246.

FIGS. 11-15 illustrate a saw blade body 414 (FIG. 12) that is formedinto a saw blade 410 (FIG. 14) according to another embodiment of theinvention. The saw blade 410 is similar to the saw blade 210; therefore,like components have been given like reference numbers plus 200 and onlythe differences between the saw blades 210, 410 will be discussed indetail. In addition, components or features described with respect toonly one or some of the embodiments described herein are equallyapplicable to any other embodiment described herein.

A method 494 of manufacturing the saw blade 410 is illustrated in FIG.11. At step 498, a blank saw blade body 414 (FIG. 12) having an edge 409is provided. In the illustrated embodiment, the edge 409 is parallel toa longitudinal axis 454 of the saw blade body 414.

As shown in FIG. 13, a strip 446 is coupled (e.g., by welding, brazing,etc.) to the edge 409 of the saw blade body 414 (step 514). In theillustrated embodiment, the strip 446 is carbide, and the saw blade body414 is a ferrous metal (e.g., steel). In other embodiments, the carbidestrip 446 may a ferrous metal that includes a greater hardness than thesaw blade body 414.

With reference to FIG. 14, tooth bodies 450, gullets 478, and anattachment portion 422 are simultaneously formed by a stamping processin the saw blade body 414 (steps 502, 506, 510). An alternative to thestamping process includes forming the tooth bodies 450, the gullets 478,and the attachment portion 422 by wire electric diode machine (EDM). Inother embodiments, the tooth bodies 450, the gullets 478, and theattachment portion 422 are formed by a laser cutting process, a grindingprocess, or the like. The illustrated attachment portion 422 includes atang 426 and an aperture 430 for connecting the saw blade 410 to areciprocating saw.

Each illustrated gullet 478 includes a first undercut portion 482 adefined by a forward edge 490 of the tooth body 450 and a secondundercut portion 482 b defined by a rear edge 486 of the tooth body 450.The forward and rear edges 486, 490 have a constant radius so theillustrated gullets 478 are generally circular. Each gullet 478 definesa gullet width 411 that is greater than an opening width 413 of anopening 415 between adjacent tooth bodies 450.

After the tooth bodies 450 and gullets 478 are formed on the saw bladebody 414, cutting teeth 418 are formed in the strip 446 and the sawblade body 414. Each strip 446 includes a first tip 434 a at a first end436 of the cutting tooth 418 that faces away from a second tip 434 b ata second end 444 of the cutting tooth 418. In other embodiments, thestrip 446 may be omitted such that the cutting teeth 418 are completelyformed within the saw blade body 414.

Each cutting tooth 418 also includes a first rake face 438 a defined bythe carbide strip 446 and the tooth body 450. The first rake face 438 ahas a first linear segment 417 a extending from the first tip 434 atoward the saw blade body 414 and a first curved segment 419 apositioned between the first linear segment 417 a and the saw blade body414. The first curved segments 419 a partially define the first undercutportions 482 a. Each cutting tooth 418 further includes a second rakeface 438 b defined by the carbide strip 446 and the tooth body 450. Thesecond rake face 438 b has a second linear segment 417 b extending fromthe second tip 434 b toward the saw blade body 414 and a second curvedsegment 419 b positioned between the second linear segment 417 b and thesaw blade body 414. The second curved segments 419 b partially definethe second undercut portions 482 b. In other embodiments, the first andsecond linear segments 417 a, 417 b may be curved segments. In theillustrated embodiment, a relief face 442 extends between the first andsecond tips 434 a, 434 b.

In general and contrary to the saw blade 210, the illustrated carbidestrip 446 is secured to the saw blade body 414, and then the toothbodies 450 and the gullets 478 are formed into the saw blade body 414such that a saw blade 410 is formed including the cutting teeth 418.Both tips 434 a, 434 b on each cutting tooth 418 are formed by the samepiece of carbide.

In other embodiments, the saw blades 10, 210, 410 may be otherlinear-edge type saw blades (e.g. a jig saw blade), or non-linear edgetype saw blades (e.g., hole saws, band saws, etc.).

Although the invention has been described in detail with reference tocertain preferred embodiments, variation and modifications exist withinthe scope and spirit of one or more independent aspects of the inventionas described. Various features and advantages of the invention are setforth in the following claims.

The invention claimed is:
 1. A saw blade comprising: a body including alongitudinal axis; an attachment portion coupled to the body, theattachment portion including a tang and an aperture configured to coupleto a reciprocating saw; a plurality of cutting teeth formed on the body,each cutting tooth including a tip at a first end of the cutting tooth,a rake face defining a line extending from the tip toward the body, at apositive rake angle relative to the longitudinal axis of the body, arelief face extending from the tip toward a second end of the cuttingtooth and sloping toward the body, and a projection at the second end ofthe cutting tooth and sloping away from the body; and a plurality ofgullets formed on the body between the plurality of cutting teeth, eachgullet of the plurality of gullets partially defined by a forward curvededge of a corresponding cutting tooth of the plurality of cutting teethand a rear curved edge of an adjacent cutting tooth of the plurality ofcutting teeth, the rear curved edge defining an undercut portion betweenthe body and the projection of the adjacent cutting tooth, the undercutportion positioned on one side of the line defined by the rake face ofthe corresponding cutting tooth and a portion of the forward curved edgepositioned on another side of the line defined by the rake face of thecorresponding cutting tooth.
 2. The saw blade of claim 1, wherein eachcutting tooth includes a tooth body and a carbide insert secured to thetooth body, wherein the tip of each cutting tooth is formed by thecarbide insert, and wherein the rake face and the relief face of eachcutting tooth is defined partially by the carbide insert of each cuttingtooth.
 3. The saw blade of claim 2, wherein each tooth body includes afirst width, and wherein each carbide insert includes a second widththat is greater than the first width.
 4. The saw blade of claim 1,wherein each projection includes a rounded end facing the rake face ofan adjacent tooth and an apex positioned between the relief face of thecorresponding cutting tooth and the rounded end.
 5. The saw blade ofclaim 4, wherein the tips of the plurality of cutting teeth define aplane, and wherein the apex of each projection is spaced a verticaldistance from the plane in a direction perpendicular to the plane. 6.The saw blade of claim 5, wherein the apex of each projection is spaceda horizontal distance from the rake face of an adjacent cutting tooth ina direction parallel to the plane.
 7. The saw blade of claim 1, whereinthe forward curved edge of the corresponding cutting tooth and the rearcurved edge of the adjacent cutting tooth have a constant radius ofcurvature.
 8. The saw blade of claim 1, wherein a first distance betweenthe projection of each cutting tooth and the tip of an adjacent cuttingtooth is less than a second distance between the rear curved edge ofeach cutting tooth at the undercut portion and the rake face of anadjacent cutting tooth.
 9. A method of manufacturing a saw blade, themethod comprising: providing a saw blade body including a longitudinalaxis; forming an attachment portion in the saw blade body, theattachment portion including a tang and an aperture configured to coupleto a reciprocating saw; forming a plurality of tooth bodies in the sawblade body, each tooth body including a rake face defining a lineextending from a first end of the tooth body toward the saw blade bodyat a positive rake angle relative to the longitudinal axis of the sawblade body, a relief face extending from the first end of the tooth bodytoward a second end of the tooth body and sloping toward the saw bladebody, and a projection at the second end of the tooth body and slopingaway from the saw blade body; and forming a plurality of gullets in thesaw blade body between the plurality of tooth bodies, each gullet of theplurality of gullets partially defined by a forward curved edge of acorresponding tooth body of the plurality of tooth bodies and a rearcurved edge of an adjacent tooth body of the plurality of tooth bodies,the rear curved edge defining an undercut portion between the saw bladebody and the projection of the adjacent tooth body, the undercut portionpositioned on one side of the line defined by the rake face of thecorresponding tooth body and a portion of the forward curved edgepositioned on another side of the line defined by the rake face of thecorresponding cutting tooth.
 10. The method of claim 9, furthercomprising coupling a plurality of carbide inserts to the plurality oftooth bodies, wherein each carbide insert is positioned between the rakeface and the relief face of each tooth body and forms a tip.
 11. Themethod of claim 10, wherein forming the plurality of tooth bodies andforming the plurality of gullets are simultaneously performed by astamping process.
 12. The saw blade of claim 7, wherein a first distancebetween the tip of the corresponding cutting tooth and the projection ofthe adjacent cutting tooth is less than a second distance between thetip of the corresponding cutting tooth and the rear curved edge of theadjacent cutting tooth at the undercut portion.
 13. The saw blade ofclaim 12, wherein each cutting tooth includes a carbide insert coupledto the body, wherein the tip of each cutting tooth is formed by thecarbide insert, and wherein the rake face and the relief face of eachcutting tooth is defined partially by the carbide insert of each cuttingtooth.
 14. A saw blade comprising: a body; a plurality of cutting teethformed on the body, each cutting tooth including a tip at a first end ofthe cutting tooth, a rake face extending from the tip toward the body, arelief face extending from the tip toward a second end of the cuttingtooth and sloping toward the body, and a projection at the second end ofthe cutting tooth and sloping away from the body; and a plurality ofgullets formed on the body between the plurality of cutting teeth, eachgullet forming an undercut portion between the body and the projectionof each cutting tooth; wherein each gullet is partially defined by aforward curved edge of one cutting tooth and a rear curved edge of anadjacent cutting tooth, wherein each rear curved edge defines oneundercut portion, wherein each forward curved edge includes a radiusmeasured from a point, wherein a portion of each forward curved edge islocated between the corresponding point and the corresponding rake facein a direction transverse to a longitudinal axis of the body.
 15. Amethod of manufacturing a saw blade, the method comprising: providing asaw blade body; forming a plurality of tooth bodies in the saw bladebody, each tooth body including a rake face extending from a first endof the tooth body toward the saw blade body, a relief face extendingfrom the first end of the tooth body toward a second end of the toothbody and sloping toward the saw blade body, and a projection at thesecond end of the tooth body and sloping away from the saw blade body;and forming a plurality of gullets in the saw blade body between theplurality of tooth bodies, each gullet forming an undercut portionbetween the saw blade body and the projection of each tooth body;wherein forming the plurality of tooth bodies and forming the pluralityof gullets are simultaneously performed by a stamping process.
 16. Themethod of claim 15, further comprising coupling a plurality of carbideinserts to the plurality of tooth bodies, wherein each carbide insert ispositioned between the rake face and the relief face of each tooth bodyand forms a tip.
 17. The saw blade of claim 14, wherein the forwardcurved edge and the rear curved edge of each gullet have a constantradius of curvature.
 18. The method of claim 9, wherein forming theplurality of gullets includes forming a constant radius of curvatureincluding the forward curved edge and the rear curved edge.